Moulded in place seal plug and suture anchor

ABSTRACT

An implantable pulse generator includes a device housing containing pulse generator circuitry and a header molded to the device housing. The header can be formed of an epoxy header material. A header component can have a first part molded in the header material to fix the header component to the header at a surface of the header and a second part extending out of the header material.

CLAIM OF PRIORITY

This application is a continuation of U.S. application Ser. No.14/327,824, filed Jul. 10, 2014, which claims priority to U.S.Provisional Application Ser. No. 61/845,507, filed Jul. 12, 2013, eachof which is herein incorporated by reference in its entirety.

TECHNICAL FIELD

The present invention relates to implantable medical devices. Morespecifically, the invention relates to molded headers for implantablemedical devices.

BACKGROUND

Various physiological functions can be managed and/or monitored usingmedical devices. Many such medical devices are implantable in a humanbody, such as implantable cardioverter-defibrillators (ICDs) orpacemakers. Such devices typically include a housing enclosing thedevice and may or may not include one or more medical electrical leadsthat can transmit electrical signals to and/or from a sensor, electrode,or other electrical component at a distal end of the medical electricallead. For example, such devices have been used in association withcardiac rhythm management, which can include cardiac pacing, cardiacdefibrillation, and/or cardiac therapy, among other procedures.

In some such devices, the housing can isolate internal components fromconductive bodily fluids after implant. Various designs for suchhousings are known in the art, some of which include headers forconnecting the medical electrical leads to the device. There exists aneed for alternative designs for headers and associated components forsuch implantable medical devices.

SUMMARY

Disclosed herein are various embodiments of medical devices and methodsof molding components on a surface of a header of a medical device.

In Example 1, a method of molding a header of an implantable pulsegenerator includes providing a mold having an inner surface defining aheader mold cavity, positioning a device housing at least partially inthe mold adjacent the header mold cavity, and positioning a headercomponent in the mold such that a first part of the header component ispositioned in the header mold cavity and a second part of the headercomponent is adjacent the mold. Header material is injected into theheader mold cavity to form the header such that the header is attachedto the device housing and the header component is attached to the headerat a surface of the header and extending out of the header when theheader material solidifies.

In Example 2, the method according to Example 1, wherein the moldcomprises silicone and the header material comprises epoxy.

In Example 3, the method according to any of Examples 1-2, wherein pulsegenerator circuitry within the device housing is connected to electricalcontacts in the header via a plurality of electrical leads prior toinjecting the header material.

In Example 4, the method according to any of Examples 1-3, wherein theheader component is a seal plug for sealing a set screw hole of theheader, and wherein the seal plug has a deformable slit extendingthrough a top of the seal plug through which a tool can be inserted andthat is substantially closed to seal and limit fluid flow through theseal plug when the tool is removed.

In Example 5, the method according to Example 4, wherein the seal plughas a substantially frustoconical surface and the header material coverssome but not all of the frustoconical surface.

In Example 6, the method according to any of Examples 4-5, and furtherincluding positioning a core in the header mold cavity, wherein the sealplug is held between the core and the mold with a portion of the sealplug seated in a core hole of the core prior to injecting the headermaterial.

In Example 7, the method according to Example 6, wherein an interfacebetween the seal plug and the core hole is substantially free of medicaladhesive.

In Example 8, the method according to Example 1, wherein the headercomponent is a suture anchor for attaching the header to tissue in amedical patient.

In Example 9, the method according to Example 8, wherein the sutureanchor comprises a line having a first end anchored in the headermaterial, a second end anchored in the header material, and a loopbetween the first and second ends extending out of the header material.

In Example 10, the method according to Example 9, and further includingforming a first knot in a first end of the line and a second knot in asecond end of the line prior to positioning the suture anchor in themold.

In Example 11, the method according to Example 9, wherein the linecomprises a braided thread.

In Example 12, the method according to any of Examples 8-11, wherein thesuture anchor comprises a flexible membrane that can be pierced by asuture needle.

In Example 13, the method according to Example 12, wherein the flexiblemembrane is porous.

In Example 14, the method according to any of Examples 8-13, wherein thesuture anchor is a first suture anchor on a first edge of the header,and the method further includes positioning a second suture anchor inthe mold such that the second suture anchor is attached via the headermaterial on the surface of the header at a second edge of the headerthat is different than the first edge of the header.

In Example 15, an implantable pulse generator includes a device housingcontaining pulse generator circuitry and a header molded to the devicehousing. The header can be formed of an epoxy header material. A headercomponent can have a first part molded in the header material to fix theheader component to the header at a surface of the header and a secondpart extending out of the header material.

In Example 16, the implantable pulse generator according to Example 15,wherein the header component is a seal plug having a deformable slitextending through a top of the seal plug through which a tool can beinserted and that is substantially closed to seal and limit fluid flowthrough the seal plug when the tool is removed.

In Example 17, the implantable pulse generator according to Example 16,wherein the seal plug is positioned in a set screw hole that comprises aheader body hole defined by the epoxy header material of the header, andwherein a distance across an outer portion of the header body hole isless than a distance across an inner portion of the header body hole.

In Example 18, the implantable pulse generator according to Example 15,wherein the header component is a suture anchor for attaching the headerto tissue in a medical patient.

In Example 19, the implantable pulse generator according to any ofExamples 15-18, wherein an interface between the header component andthe header is substantially free of medical adhesive.

In Example 20, a pulse generator for a cardiac rhythm management systemcan include a device housing and a header molded to the device housing.The header can be formed of an epoxy header material that defines a setscrew hole. A distance across an outer portion of the set screw hole isless than a distance across an inner portion of the set screw hole. Aset screw can be positioned in the header and aligned with the set screwhole. A seal plug can have a deformable slit extending through the sealplug for receiving a tool to tighten the set screw. The seal plug can bemolded in the epoxy header material at a surface of the header to fixthe seal plug to the header with a plug top of the seal plug extendingout of the surface of the header.

While multiple embodiments are disclosed, still other embodiments of thepresent invention will become apparent to those skilled in the art fromthe following detailed description, which shows and describesillustrative embodiments of the invention. Accordingly, the drawings anddetailed description are to be regarded as illustrative in nature andnot restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a cardiac rhythm management (CRM) systemaccording to one embodiment of the present invention.

FIG. 2A is a perspective view of one embodiment of a pulse generator foruse in the CRM system of FIG. 1, with an opaque header body.

FIG. 2B is a perspective view of another embodiment of a pulse generatorfor use in the CRM system of FIG. 1, with a transparent header body.

FIG. 3 is a sectional view of a portion of one embodiment of the headerbody.

FIG. 4 is a sectional view of the portion of the header body of FIG. 3positioned in a mold.

FIG. 5A is a sectional view of the header body and one embodiment of asuture anchor positioned in the mold.

FIG. 5B is a sectional view of the header body and another embodiment ofa suture anchor positioned in the mold.

FIG. 5C is a sectional view of the header body and another embodiment ofa suture anchor positioned in the mold.

While the invention is amenable to various modifications and alternativeforms, specific embodiments have been shown by way of example in thedrawings and are described in detail below. The intention, however, isnot to limit the invention to the particular embodiments described. Onthe contrary, the invention is intended to cover all modifications,equivalents, and alternatives falling within the scope of the inventionas defined by the appended claims.

DETAILED DESCRIPTION

FIG. 1 is a schematic view of a cardiac rhythm management (CRM) system10 according to one embodiment. As shown in FIG. 1, the CRM system 10includes a pulse generator 12 coupled to a plurality of leads 14 and 16deployed in a patient's heart 18. The pulse generator 12 includes ahousing 20 and a header 22 mounted on the housing 20. As further shownin FIG. 1, the heart 18 includes a right atrium 24 and a right ventricle26 separated by a tricuspid valve 28. During normal operation of theheart 18, deoxygenated blood is fed into the right atrium 24 through thesuperior vena cava 30 and the inferior vena cava 32. As further shown,the heart 18 includes a left atrium 34, which receives oxygenated bloodfrom the lungs, and a left ventricle 36, which pumps the oxygenatedblood to the body.

The leads 14 and 16 are medical electrical leads that operate to conveyelectrical signals and stimuli between the heart 18 and the pulsegenerator 12. The header 22 of the pulse generator 12 is an outputterminal header with cores 38 and 40 substantially encapsulated in aheader body 42. The cores 38 and 40 are output terminal cores forreceiving proximal ends of the leads 14 and 16, respectively. In theillustrated embodiment, a distal end of the lead 14 is implanted in theright ventricle 26, and a distal end of the lead 16 is implanted in theright atrium 24. In other embodiments, the CRM system 10 may includeadditional leads, e.g., a lead extending into a coronary vein forstimulating the left ventricle in a bi-ventricular pacing or cardiacresynchronization therapy (CRT) system. As shown, the leads 14 and 16enter the superior vena cava 30, and are implanted in the rightventricle 26 and right atrium 24, respectively.

The pulse generator 12 can be implanted subcutaneously within animplantation location or pocket in the patient's chest or abdomen. Thepulse generator 12 can be any implantable medical device known in theart, or later developed, for delivering an electrical therapeuticstimulus to the patient. In various embodiments, the pulse generator 12can be a neurostimulation device, a pacemaker, a CRT device, animplantable cardiac defibrillator, and/or can include both pacing, CRTand/or defibrillation capabilities (e.g., a CRT-D device).

In some embodiments the CRM system 10 can be configured to stimulatecardiac tissue and/or sense certain physiological attributes of theheart. However, in discussing embodiments of the present disclosure,reference is made primarily to stimulating body tissues. Those ofordinary skill in the art will recognize that some or all of theconfigurations can also be used to receive electrical signals from thebody.

FIG. 2A is a perspective view of the pulse generator 12 with the header22 having an opaque header body 42. The header 22 has a plurality ofreceptacles 44, 46, and 48 in the header body 42. The receptacles 44,46, and 48 are terminal holes that allow lead terminal pins of leads,such as the leads 14 and 16 (shown in FIG. 1) to be inserted into cores,such as the cores 38 and 40 (shown in FIG. 1). Because the header body42 is opaque, the cores 38 and 40 are not visible in FIG. 2A.

The header 22 also has a plurality of holes 50, 52, and 54, which areset screw holes that allow access to set screws (not shown in FIG. 2A)that can be tightened to fasten the lead terminals of the leads 14 and16 in the cores 38 and 40. Plugs 56, 58, and 60 are seal plugs that areinserted into and seal the holes 50, 52, and 54, respectively.

In the illustrated embodiment, the header body 42 has an outer surface62 and an indented surface 64 sunken below the outer surface 62. Theouter surface 62 and the indented surface 64 both face substantiallyoutward from the header body 42. The indented surface 64 surrounds theholes 50, 52, and 54. The plugs 56, 58, and 60 are positioned in theholes 50, 52, and 54 so as to extend above the indented surface 64 but,in the illustrated embodiment, do not extend substantially above theouter surface 62.

The header body 42 can also have one or more suture anchors 66 and 68that can be used to hold the pulse generator 12 in place when implantedin a human body of a medical patient. Sutures or other fasteners canattach one or more of the suture anchors 66 and 68 of the header 22 totissue of the medical patient. In the illustrated embodiment, the sutureanchor 66 is positioned on a rear edge of the header 22 and the sutureanchor 68 is positioned on a top edge of the header 22. In alternativeembodiments, the suture anchors 66 and 68 can be positioned at otherlocations on the header 22 as suitable for the application. In furtheralternative embodiments, header 22 can have fewer or greater than twosuture anchors. For example, the header 22 can include a third sutureanchor (not shown) positioned on a front edge of the header 22, oppositeof the suture anchor 66. When the pulse generator 12 is implanted intothe medical patient, a surgeon can choose to use one of the multiplesuture anchors deemed most appropriate for the application.Alternatively, the surgeon can choose to attach both suture anchors 66and 68 (or all three suture anchors in embodiments with three sutureanchors) in order to provide further support to the pulse generator 12in the patient. Attaching via multiple suture anchors can be beneficialin applications where the specific position and/or orientation of thepulse generator 12 is important. Moreover, attaching via multiple sutureanchors can be beneficial for reducing the risk of malfunction in a caseof twiddler's syndrome, whereby a patient undesirably manipulates thepulse generator 12 in a way that spins the pulse generator 12 within thepatient's body which can result in the twisting and/or dislodging of oneor more of the leads 14 and 16 (shown in FIG. 1) and/or causingundesirable nerve stimulation.

FIG. 2B is another perspective view of a pulse generator 12′, which issimilar to the pulse generator 12 (shown in FIG. 2A) except that thepulse generator 12′ has a header body 42′ that is transparent. Becausethe header body 42′ is transparent, the cores 38 and 40, as well asanother core 70, are visible. A plurality of electrical leads 72 connectpulse generator circuitry (not shown) within the housing 20 toelectrical contacts 74 on the cores 38, 40, and 70. Thus, the pulsegenerator 12′ can transmit electrical signals to and from leads (such asthe leads 14 and 16, shown in FIG. 1) connected to the header 22′.

Although the header 22′ is shown in FIG. 2B as having three cores (thecores 38, 40, and 70) for connecting to three leads (not shown), theheader 22′ can have one, two, or more than three cores as suitable for aparticular application. The cores 38, 40, and 70 are illustrated asthree distinct cores. Alternatively, the cores 38, 40, and 72 can becombined as a single core having multiple receptacles (such as thereceptacles 44, 46, and 48 as shown in FIG. 2A).

FIG. 3 is a sectional view of the header 22, showing the header body 42,the core 70, and the plug 60. The core 70 contains a lead bore cavity 76and a tip block 78. An inner seal 80 provides a substantially fluidtight seal between the core 70 and the lead bore cavity 76. A threadedfastener 82 has a head 84 connected to a threaded shaft 86. The threadedfastener 82 is a set screw threadedly engaged with the tip block 78. Thethreaded fastener 82 can be tightened so as to fasten a lead terminalpin on a proximal end of an electrical lead (such as the leads 14 and 16of FIG. 1) in the lead bore cavity 76. The threaded fastener 82, the tipblock 78, and the lead bore cavity 76 can be made of electricallyconductive metal so as to conduct signals to and from the electricallead.

The hole 54 is a set screw hole that extends through the header 22. Thehole 54 includes a header body hole 88 extending through and defined bythe header body 42 and a core hole 90 extending through and defined bythe core 70. The core hole 90 extends from a core interior 92 to thecore outer surface 94. The header body hole 88 extends from a body innersurface 96, which is adjacent and molded to the core outer surface 94,to the indented surface 64 (or the outer surface 62) of the header body42. The header body hole 88 has a hole outer portion 100 and a holeinner portion 102. The indented surface 64 of the header body 42 isnearer the hole outer portion 100 than the hole inner portion 102. Adistance across the hole outer portion 100 is less than a distanceacross the hole inner portion 102.

The plug 60 is positioned in the header body hole 88 and the core hole90. The plug 60 has a plug outer portion 104 aligned with the hole outerportion 100 and has a plug inner portion 106 aligned with the hole innerportion 102. A distance across the plug outer portion 104 issubstantially equal to the distance across the hole outer portion 100. Adistance across the plug inner portion 106 is substantially equal to thedistance across the hole inner portion 102. Thus, the distance acrossthe plug outer portion 104 is less than the distance across the pluginner portion 106.

In the illustrated embodiment, the plug 60 is substantially cylindricalat plug inner portion 106 and then tapers from the plug inner portion106 to the plug outer portion 104 such that the plug 60 is substantiallyfrustoconical at the plug outer portion 104. Thus, the distance acrossthe plug outer portion 104 is a diameter of the plug outer portion 104and the distance across the plug inner portion 106 is a diameter of theplug inner portion 106. The header body hole 88 is formed to the shapeof the plug 60 where the header body 42 contacts the plug 60. Thus inthe illustrated embodiment, the header body hole 88 is substantiallycylindrical at the hole inner portion 102 and then tapers from the holeinner portion 102 to the hole outer portion 100 such that the headerbody hole 88 is substantially frustoconical near the hole outer portion100. The header body 42 is an epoxy outer layer overmolded over the core70 that covers some but not all of a frustoconical surface 108 of theplug 60 at the plug outer portion 104. In alternative embodiments, theplug 60 can have a shape different than as illustrated. For example, theplug 60 can have multiple cylindrical sections connected by a radialstep. Alternatively, the plug 60 can have a larger, smaller, oradditional frustoconical portion. Alternatively, the plug 60 can have ashape substantially that of a square pyramid.

In the illustrated embodiment, the plug 60 has a plug top 110 and a plugbottom 112 opposite the plug top 110. The plug 60 defines a concaveindentation 114 on the plug top 110 and a plug cavity 116 on the plugbottom 112. A slit 118 extends from the concave indentation 114 on theplug top 110, through the plug 60, to the plug cavity 116. The head 84of the threaded fastener 82 is positioned at least partially in the plugcavity 116. Under normal operation, the slit 118 is substantially closedto seal and limit fluid flow through the plug 60. The slit 118 isdeformable, allowing a tool (not shown) to be inserted through the slit118 into the head 84 of the threaded fastener 82 to turn the threadedfastener 82. When the tool is removed, the slit 118 can resilientlyreturn to its original, sealed configuration. The plug 60 can be made ofa resilient polymer material suitable for sealing the hole 54.

The shapes of the plug 60 and the header body hole 88 can help retainthe plug 60 in the hole 54. Because the distance across the plug outerportion 104 (and across the hole outer portion 100) is smaller than thedistance across the plug inner portion 106 (and the hole inner portion102), the plug 60 can be prevented from falling out of the header bodyhole 88 during normal operation of the pulse generator 12 (shown in FIG.1). The plug 60 can be retained in the header body hole 88 without usingmedical adhesive between the plug and either the header body hole 88 orthe core hole 90.

FIG. 4 is a sectional view of a portion of the header 22, showing theheader body 42, the core 70, and the plug 60, in a mold 120. The mold120 has an inner surface 122 defining a header mold cavity 124 that hassubstantially the same shape as the header 22. The mold 120 can alsodefine a housing cavity (not shown) configured to hold the housing 20adjacent the header mold cavity 124. In one embodiment, the mold 120 canbe formed of a silicone material. For example, the mold 120 can be madefrom a two part liquid injection silicone. In another embodiment, themold 120 can be made from a compression molded silicone. In anotherembodiment, the mold 120 can be made from a room temperature vulcanizingsilicone. In one embodiment, the mold 120 can consist or consistessentially of silicone. In alternative embodiments, the mold 120 caninclude other materials in addition to or instead of silicone. In afurther alternative embodiment, the mold 120 can be formed of anothermaterial suitable for the application.

The header 22 can be formed by first premolding the core 70 usinganother mold (not shown). The core 70 can be molded in the shapesubstantially as illustrated, including the core hole 90. The housing 20can be positioned at least partially in the housing cavity of the mold120, adjacent the header mold cavity 124, and the core 70 can bepositioned in the header mold cavity 124. The plug 60 can be positionedin the mold 120 such that the plug bottom 112 is in the core hole 90,the plug top 110 is adjacent the inner surface 122, and the plug outerportion 104 and the plug inner portion 106 are in the header mold cavity124 between the mold 120 and the core 70.

Header material can then be injected into the header mold cavity 124 toform the header body 42 such that the header 22 is attached to thehousing 20. The header material can flow over the core 70 tosubstantially encapsulate the core 70. The header material can flowaround the plug 60 so as to retain the plug 60 in the header 22 at asurface of the header 22. The header material can partially cover theplug 60, including a portion of the frustoconical surface 108, and leavea portion of the plug 60, including the plug top 110 and the concaveindentation 114, exposed. Thus, the plug top 110 extends out of theheader 22 when the header material solidifies. The pulse generator 12can then be removed from the mold, with the header 22 attached to thehousing 20 and the plug 60 retained in the header 22. The plug 60 isthus attached and retained in the header 22 without use of medicaladhesive in an interface between the plug 60 and the core 70 or betweenthe plug 60 and the header body 42. In one embodiment, the headermaterial can be an epoxy resin. In an alternative embodiment, the headermaterial can be another material suitable for the application. In theillustrated embodiment, the plug 60 is held between the core 70 and themold 120 with the plug bottom 112 of the plug 60 seated in the core hole90. In an alternative embodiment, the core 70 can be omitted and theplug 60 can be seated in a version of the header 22 configured withoutcores.

FIG. 5A is a sectional view of the header 22, showing the header body 42and the suture anchor 68 in the mold 120. In the illustrated embodiment,the suture anchor 68 is a monofilament line that includes a suture loop126 between two anchor ends 128 and 130. In the illustrated embodiment,the anchor ends 128 and 130 are reverse tapered, having a largerdiameter at the anchor ends 128 and 130 than near the suture loop 126.The anchor ends 128 and 130 are potted in the header body 42 so as toretain the suture anchor 68 to the header body 42. The suture loop 126extends out of the header body 42, allowing the suture loop 126 to besutured to tissue in the body of the patient. The suture loop 126 can bemade of a material suitable to be pierced by a suture needle when beingsutured to body tissue. In the illustrated embodiment, the suture anchor68 is made of a monofilament polymer material. In an alternativeembodiment, the suture anchor 68 can be a braided thread. In variousembodiments, the suture anchor 68 can be made of other materialssuitable for the application, including materials that are absorbableand/or materials that are non-absorbable by the body of the patient.

The suture anchor 68 can be attached to the header body 42 in a mannersimilar to that of attaching the plug 60 (shown in FIGS. 3 and 4) to theheader body 42. The housing 20 can be positioned at least partially inthe housing cavity of the mold 120, adjacent the header mold cavity 124.The suture anchor 68 can be positioned in the mold 120 such that theanchor ends 128 and 130 are in the header mold cavity 124 and the loop126 is positioned in a suture anchor cavity 132 defined by the innersurface 122 of the mold 120. In the illustrated embodiment, the sutureanchor cavity 132 is substantially arch-shaped. The suture anchor 68 canbe held relatively tightly in the suture anchor cavity 132, with thesuture loop 126 adjacent the inner surface 122. The suture anchor 68 canbe used in headers 22 with and without cores, such as the core 70. Inembodiments with the core 70, the core 70 can also be positioned in theheader mold cavity 124.

Header material can then be injected into the header mold cavity 124 toform the header body 42 such that the header 22 is attached to thehousing 20. The header material can flow over the core 70 tosubstantially encapsulate the core 70. The header material can flowaround the suture anchor 68 so as to retain the suture anchor 68 in theheader 22 at a surface of the header 22. The header material canpartially cover the suture anchor 68, including the anchor ends 128 and130, and leave a portion of the suture anchor 68, including the sutureloop 126, exposed. Thus, the suture loop 126 extends out of the header22 when the header material solidifies. The pulse generator 12 can thenbe removed from the mold, with the header 22 attached to the housing 20and the suture anchor 68 retained in the header 22.

FIG. 5B is a sectional view of the header 22, showing the header body 42and a suture anchor 134 in the mold 120. The suture anchor 134 issubstantially the same as the suture anchor 68 (shown in FIG. 5A),except that the suture anchor 134 is tied to form knots at anchor ends136 and 138 prior to positioning the suture anchor 134 in the mold 120.Because the anchor ends 136 and 138 are knotted and potted in the headerbody 42, the suture anchor 134 can be retained in the header body 42. Asuture loop 140 extends between the anchor ends 136 and 138. Like thesuture loop 126 (shown in FIG. 5A), the suture loop 140 extends out ofthe header body 42, allowing the suture loop 140 to be sutured to tissuein the body of the patient. The suture anchor 134 can be attached to theheader body 42 using the same mold 120 and method described above withrespect to the suture anchor 68.

FIG. 5C is a sectional view of the header 22, showing the header body 42and a suture anchor 142 in a mold 144. The suture anchor 142 issubstantially similar to the suture anchors 68 and 124 (shown in FIGS.5A and 5B), except that the suture anchor 142 a flexible membrane. Inthe illustrated embodiment, the suture anchor 142 is a substantiallyrectangular sheet with a suture portion 146 and an anchor portion 148.The anchor portion 148 is potted in the header body 42 to retain thesuture anchor 142 in the header body 42. The suture portion 146 extendsout of the header body 42, allowing the suture portion 146 to be suturedto tissue in the body of a medical patient. In the illustratedembodiment, the suture anchor 142 is a knitted mesh with a plurality ofpores 150. In the illustrated embodiment, the pores 150 are positionedin both the suture portion 146 and the anchor portion 148. The pores 150in the suture portion 146 can allow for the suture portion 146 to bepierced by a suture needle. The pores 150 in the anchor portion 148 canallow for header material to flow into the pores 150 to providestructural support for retaining the suture anchor 142 in the headerbody 42. In alternative embodiments, the suture anchor 142 can have adifferent shape and configuration suitable for the application.

In one embodiment, the suture portion 146 of the suture anchor 142 canbe relatively short, but long enough to allow the suture portion 146 tobe attached to tissue via sutures. In another embodiment, the sutureportion 146 can be relatively long. For example, in one embodiment thesuture portion 146 can have sufficient length to be able to wrap arounda bundle of leads (such as the leads 14 and 16 shown in FIG. 1) and thenbe attached to tissue via sutures. In that embodiment, the suture anchor142 can be used to attach both the pulse generator 12 (shown in FIG. 1)and the bundle of leads to tissue.

In some embodiments, the suture portion 146 of the suture anchor 142 canbe coated with antibiotics that dissolve when implanted in the medicalpatient. Antibiotics can thus be delivered locally at a suture locationto help reduce risk of infection due to implantation. In alternativeembodiments, antibiotics can be omitted.

The suture anchor 142 can be attached to the header body 42 using themold 144, which is similar to the mold 120 (shown in FIGS. 5A and 5B),except that the mold 144 has an inner surface 152 that defines a sutureanchor cavity 154 sized and shaped for the suture anchor 142. In theillustrated embodiment, the suture anchor cavity 154 is substantiallyrectangular with a relatively shallow depth so as to hold the sutureanchor 68 relatively tightly in the suture anchor cavity 154, with thesuture portion 146 adjacent the inner surface 152. The inner surface 152of the mold 144 also defines a header mold cavity 156. Header materialcan then be injected into the header mold cavity 156 to form the headerbody 42 such that the header 22 is attached to the housing 20 and thesuture anchor 142 is attached to the header body 42.

Thus, the above description includes methods to mold components in placeon a header body so as to be attached at a surface of the header body.These methods can be performed with seal plugs used to seal set screwholes. This can allow such seal plugs to be retained in the header bodyin a way that is relatively reliable and without use of medicaladhesive. These methods can also be used to attach a suture anchor tothe header body. Such suture anchors can take one of a number ofconfigurations and can allow attachment at a variety of locations on theheader body. Attaching suture anchors as described can allow for headersto be formed without including suture attachment holes extending throughthe header body. Use of a silicone mold and epoxy header material canallow the header to be reliably attached to the housing of the medicaldevice and allow one or more components, such as seal plugs and sutureanchors, to be reliably attached to a surface of the header in the sameinjection molding process.

Various modifications and additions can be made to the exemplaryembodiments discussed without departing from the scope of the presentinvention. For example, while the embodiments described above refer toparticular features, the scope of this invention also includesembodiments having different combinations of features and embodimentsthat do not include all of the described features. Accordingly, thescope of the present invention is intended to embrace all suchalternatives, modifications, and variations as fall within the scope ofthe claims, together with all equivalents thereof.

We claim:
 1. A method of molding a header of an implantable pulsegenerator, the method comprising: providing a mold having an innersurface defining a header mold cavity; positioning a device housing atleast partially in the mold adjacent the header mold cavity; positioninga header component in the mold such that a first part of the headercomponent is positioned in the header mold cavity and a second part ofthe header component is adjacent the mold; and injecting header materialinto the header mold cavity to form the header such that the header isattached to the device housing and the header component is attached tothe header at a surface of the header and extending out of the headerwhen the header material solidifies.
 2. The method of claim 1, whereinthe mold comprises silicone and the header material comprises epoxy. 3.The method of claim 1, wherein pulse generator circuitry within thedevice housing is connected to electrical contacts in the header via aplurality of electrical leads prior to injecting the header material. 4.The method of claim 1, wherein the header component is a seal plug forsealing a set screw hole of the header, and wherein the seal plug has adeformable slit extending through a top of the seal plug through which atool can be inserted and that is substantially closed to seal and limitfluid flow through the seal plug when the tool is removed.
 5. The methodof claim 4, wherein the seal plug has a substantially frustoconicalsurface and the header material covers some but not all of thefrustoconical surface.
 6. The method of claim 4, and further comprising:positioning a core in the header mold cavity, wherein the seal plug isheld between the core and the mold with a portion of the seal plugseated in a core hole of the core prior to injecting the headermaterial.
 7. The method of claim 6, wherein an interface between theseal plug and the core hole is substantially free of medical adhesive.8. The method of claim 1, wherein the header component is a first headercomponent, the method further includes: positioning a second headercomponent in the mold, wherein the second header component is a sutureanchor for attaching the header to tissue in a medical patient.
 9. Themethod of claim 8, wherein the mold includes a suture anchor cavity. 10.The method of claim 9, wherein the suture anchor comprises a line havinga first end, a second end, and a loop between the first and second ends.11. The method of claim 10, wherein positioning the suture anchor in themold includes: positioning the loop in the suture anchor cavity suchthat the first and second ends of the suture anchor are positionedwithin the header mold cavity.
 12. The method of claim 10, wherein thefirst end is anchored in the header material, the second end anchored inthe header material, and the loop between the first and second endsextends out of the header material.
 13. The method of claim 10, whereina diameter of the first and second ends of the suture anchor are greaterthan a diameter of the suture anchor along the loop.
 14. The method ofclaim 10, and further comprising: forming a first knot in the first endof the line and a second knot in the second end of the line prior topositioning the suture anchor in the mold.
 15. The method of claim 10,wherein the line comprises a braided thread.
 16. The method of claim 8,wherein the suture anchor comprises a flexible membrane that can bepierced by a suture needle.
 17. The method of claim 16, wherein theflexible membrane is porous.
 18. The method of claim 8, wherein thesuture anchor is a first suture anchor on a first edge of the header,and further comprising: positioning a second suture anchor in the moldsuch that the second suture anchor is attached via the header materialon the surface of the header at a second edge of the header that isdifferent than the first edge of the header.
 19. A method of molding aheader of an implantable pulse generator, the method comprising:providing a mold having an inner surface defining a header mold cavityand a suture anchor cavity; positioning a device housing at leastpartially in the mold adjacent the header mold cavity; positioning afirst header component in the mold such that a first part of the firstheader component is positioned in the header mold cavity and a secondpart of the header component is adjacent the mold; positioning a secondheader component in the mold such that a first part of the second headercomponent is positioned in the suture anchor cavity of the mold and asecond part of the second header component is positioned in the headermold cavity; and injecting header material into the header mold cavityto form the header such that the header is attached to the devicehousing, the first header component is attached to the header at asurface of the header and extending out of the header when the headermaterial solidifies, and the second header component is attached to theheader such that the first part of the second header component ispositioned in the header and the second part of the second headercomponent is extending out of the header when the header materialsolidified.
 20. The method of claim 19, wherein the first headercomponent is a seal plug for sealing a set screw hole of the header, andthe second header component is a suture anchor for attaching the headerto tissue in a medical patient.